Knee brace

ABSTRACT

A knee brace for use by athletes or others requiring protection and support of the knee. The knee brace includes a base and a spider member. The base is comprised of elastic material and configured to closely fit around portions of the knee and adjacent leg portions. A spider member having upper and lower pairs of tensioning straps is fastened to the interior surface of the base, with the tensioning straps extending through upper and lower apertures in the base for detachable attachment to the exterior surface of the base.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation of application Ser. No. 14/750,949filed Jun. 25, 2015 and now pending (which claims priority toprovisional application No. 62/016,750 filed Jun. 25, 2014 andprovisional application No. 62/016,765 filed Jun. 25, 2014) and is acontinuation-in-part of application Ser. No. 14/192,713 filed Feb. 27,2014 (which claims priority to provisional application No. 61/771,228filed Mar. 1, 2013 and provisional application No. 61/770,926 filed Feb.28, 2013). Each of the patent applications identified above isincorporated here by reference in its entirety for continuity ofdisclosure.

FIELD OF THE INVENTION

This invention relates generally to the field of articles worn bypersons to reduce the likelihood, severity, or exacerbation of injury tothe body, and more specifically to the field of braces worn on the knee.

BACKGROUND OF THE INVENTION

Flexible knee braces are used by athletes and other persons engaged invigorous physical activity to protect the knee from injury and to avoidexacerbation of existing injury. The knee is one of the most heavilyused joints of the body, as it is used in any activity that involveswalking or running. The knee is also a common subject of injury, due tothe relatively high levels of stress it must bear. During normalambulation, in occupations involving physical labor, and especiallyduring strenuous sports, the knee can undergo abnormal motions as aresult of quick changes in direction, fatigue, uneven surfaces, orimpacts. These abnormal motions can cause sprains or more seriousinjuries, including dislocation, stretching, or tearing of the tissuesthat make up the knee.

Several different types of abnormal motion can cause injury to the knee.First, hyperextension of the knee joint can occur, wherein the kneeflexes in its normal front to back fashion but beyond its normal rangeof motion. A second type of abnormal motion is axial rotation, whereinthe lower leg is twisted rotationally relative to the thigh about theknee joint. A third type of abnormal motion is lateral flexure of thelower leg relative to the thigh, wherein the knee joint flexes from sideto side instead of the normal front to back motion. In addition,abnormal motion of the patella (kneecap) can result in injuries such aschondromalacia patella, which is a softening or degeneration of theundersurface of the patella, and dislocation of the patella, also knownas subluxation of the patella.

Devices to protect the knee against abnormal motions have been used formany years, in a variety of specific embodiments which vary in theirabilities to protect against the different types of abnormal motions.Besides protecting the knee against abnormal motions, the devicessometimes provide additional benefits such as insulating the knee tokeep it warm, protecting the knee against impact, or compressing theknee to reduce discomfort. However, the protections afforded by thesedevices against abnormal motion are often accompanied by a reduction inrange or ease of normal motion. These devices can also have otherundesirable aspects such as added weight on the leg, potential forself-injury or injury to others caused by rigid components, difficultyof application and removal, cost, appearance, and irritation or chafingof the skin.

For these reasons, there has long been motivation to find an improvedknee brace which can protect the knee from abnormal motions withoutaffecting the range or ease of normal motion, while avoiding theundesirable aspects of prior art devices.

SUMMARY OF THE INVENTION

In a first embodiment, a knee brace according to the present inventionincludes a base and a spider member having pairs of upper and lowertensioning straps, wherein the spider member is permanently fastened tothe interior surface of the base.

According to another aspect of the invention, a knee brace according tothe present invention includes a base and a spider member having pairsof upper and lower tensioning straps, wherein the spider member ispermanently fastened to the base by a plurality of stitches through themid-line axes of the base and spider member.

According to another aspect of the invention, a knee brace according tothe present invention includes a base with pairs of upper and lowerapertures, and a spider member positioned between the base and the legof the person when worn and having pairs of upper and lower tensioningstraps, wherein the tensioning straps extend through the apertures inthe base when the brace is worn.

In a second embodiment, a knee brace according to the present inventionincludes a base, and a shaped tensioning member formed of a syntheticfiber that is relatively elastic in all directions, for example of thetype known as spandex in the United States or elasthane, or sold underthe trademark LYCRA®, although this is not required and other materialscould be used. The tensioning member is permanently fastened to theinterior surface of the base and has free ends extending throughapertures in the base where they can be fastened to the exterior surfaceof the base using hook-and-loop fastening material. In a thirdembodiment, one or more resilient stays can also be provided foradditional support.

In a fourth embodiment, a knee brace according to the present inventionincludes a base, an external mesh layer, and a multi-part internalspider member comprising a shaped tensioning member formed of asynthetic fiber that is relatively elastic in all directions, forexample, of material of the type known as spandex in the United Statesor elasthane, or sold under the trademark LYCRA®, although this is notrequired and other materials could be used. The shaped tensioning memberhas a central portion that is permanently fastened to the interiorsurface of the base, and has straps extending through apertures in thebase to (free) strap ends that are fastenable to the exterior surface ofthe base using hook-and-loop fastening material. The straps may includeinelastic portions, for example near the second (free) ends.

In a fifth embodiment, a knee brace according to the present inventionincludes a base, an external mesh layer, and upper and lower crossedstraps formed of a synthetic fiber that is relatively elastic in alldirections, for example, of material of the type known as spandex in theUnited States or elasthane, or sold under the trademark LYCRA®, althoughthis is not required and other materials could be used. The crossedstraps have first ends permanently fastened to the interior surface ofthe base and extending through apertures in the base to second (free)ends that are fastenable to the exterior surface of the base usinghook-and-loop fastening material. The straps may include inelasticportions, for example near the second (free) ends.

Inelastic portions of the straps can be formed by simply substitutingelastic material with inelastic material at the locations where aninelastic portion is desired, for example extending from a location nearthe aperture when worn to the free ends. Alternatively, an inelasticportion can be formed by sandwiching and/or overlapping portions of theelastic material with an additional layer of inelastic material straps.If overlapped or sandwiched, one side of the resulting sandwich can beleft open to form a pocket to hold small items such as keys, accessfobs, ID or credit cards, smart devices (for example fitness trackers)or visible flair such as brightly colored items, reflectors, blinkinglights, glow sticks, or other lighting. In such a case the external meshlayer is preferably made of a mesh or other transparent or translucentmaterial to allow the flair or lighting to be seen. One or morereflective patches can also be provided to enhance visibility of thewearer.

Further objects, features, and advantages of the invention will beapparent from the following detailed description when taken inconjunction with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

In the drawings:

FIG. 1A is a plan view of a prior art knee brace, laid flat to exposethe exterior surface of the brace;

FIG. 1B is a plan view of the prior art knee brace of FIG. 1A, laid flatto expose the interior surface of the brace;

FIG. 2A is a plan view of a first embodiment of a knee brace accordingto the present invention, laid flat to expose the exterior surface ofthe brace;

FIG. 2B is a plan view of the knee brace of FIG. 2A, laid flat to exposethe interior surface of the brace;

FIG. 3A is a front view of the knee brace of FIGS. 2A-2B, applied to theleg of a person with the base mounting straps fastened, but with thespider straps unfastened;

FIG. 3B is a front view of the knee brace of FIGS. 2A-2B, applied to theleg of a person with the base mounting straps fastened, and with thespider straps fastened as well;

FIG. 4A is a side view of the knee brace of FIGS. 2A-2B, applied to theleg of a person with the base mounting straps fastened, but with thespider straps unfastened;

FIG. 4B is a side view of the knee brace of FIGS. 2A-2B, applied to theleg of a person with the base mounting straps fastened, and with thespider straps fastened as well

FIG. 5A is a plan view of a second embodiment of a knee brace accordingto the present invention, having a shaped tensioning member formed of asynthetic fiber that is relatively elastic in all directions andpermanently fastened to the interior surface of the base, with the bracelaid flat to expose the exterior surface of the brace;

FIG. 5B is a plan view of the knee brace of FIG. 5A, laid flat to exposethe interior surface of the brace;

FIG. 5C is a plan view of a shaped tensioning member for use in the kneebrace of FIGS. 5A-5B;

FIGS. 5D-5E are perspective views of an aperture reinforcement base andbacking, respectively, for use in the knee brace of FIGS. 5A-5B;

FIG. 6A is a plan view of a third embodiment of a knee brace accordingto the present invention, having upper and lower crossed straps alongwith resilient stays, with the brace laid flat to expose the exteriorsurface of the brace;

FIG. 6B is a plan view of the knee brace of FIG. 6A, laid flat to exposethe interior surface of the brace;

FIG. 7A is a plan view of a fourth embodiment of a knee brace accordingto the present invention, having an external mesh layer and an internalshaped tensioning member having both elastic and inelastic components,with the brace laid flat to expose the exterior surface of the brace;

FIG. 7B is a plan view of the knee brace of FIG. 7A, laid flat to exposethe interior surface of the brace;

FIG. 7C is a plan view of the knee brace of FIG. 7A, laid flat to exposethe exterior surface of the brace and with the external mesh layerremoved to reveal the construction of the internal shaped tensioningmember that may have both elastic and inelastic components;

FIG. 7D is a plan view of an external mesh layer for use in the kneebraces of FIGS. 7A-7C;

FIG. 7E shows a resilient stay member for use in the knee brace of FIGS.6A-6B, 7A-7C, and 8A-8C;

FIG. 8A is a plan view of a fifth embodiment of a knee brace accordingto the present invention, having an external mesh layer and upper andlower crossed straps that may have both elastic and inelastic portions,with the brace laid flat to expose the exterior surface of the brace;

FIG. 8B is a plan view of the knee brace of FIG. 8A, laid flat to exposethe interior surface of the brace;

FIG. 8C is a plan view of the knee brace of FIG. 8A, laid flat to exposethe exterior surface of the brace and with the external mesh layerremoved to reveal the construction of the upper and lower crossed strapsthat may have both elastic and inelastic portions; and

FIG. 8D is a plan view of an external mesh layer for use in the kneebrace of FIGS. 8A-8C.

DETAILED DESCRIPTION OF THE INVENTION

Referring to the drawings, FIGS. 1A and 1B show a prior art knee brace20, similar to the design taught in U.S. Pat. No. 5,472,413, thecontents of which are hereby incorporated by reference. The prior artknee brace 20 includes a base member 22 and a spider member 24, eachmade by cutting planar sheets 26 of an elastomeric material into thedesired shapes. The exterior surface 31 of the base member 22 ispreferably covered with fabric bearing fiber loops 28 that adheres tohook-type material when the fiber loops and hook-type material arepressed together.

The base 22 of the prior art knee brace 20 has a base central portion 30extending vertically from an upper edge 36 to a lower edge 38, and has amid-line axis 40 running vertically down the middle of base centralportion 30. The base 22 includes a first upper mounting strap 32A, asecond upper mounting strap 32B, a first lower mounting strap 34A, and abase second lower mounting strap 34B extending from the central portion30.

As perhaps best shown in FIG. 1B which shows the interior surface 39 ofthe base 22, the first upper mounting strap 32A and first lower mountingstrap 34A terminate in hook-type strap fastening tabs 46 suitable fordetachable attachment to the fabric bearing fiber loops 28 on theexterior surface 31 of the base member 22. The strap fastening tabs 46are sewn to the mounting straps with stitches 48.

The base also has a kneecap opening 52 to receive the kneecap when thebrace is worn, it may be formed to include a recess 74 to preventbunching when the brace is worn, and the base preferably includes edgebinding 76, although none of these features are required.

As perhaps best shown in FIG. 1A which shows the exterior surface 31 ofthe base 22, the prior art knee brace 20 includes a spider member 24.The spider member 24 has a spider member central portion 54 extendingvertically from an upper edge 56 to a lower edge 58, and has a mid-lineaxis 60 running vertically down the middle of the spider member centralportion 54. The spider member 24 is permanently attached to the exteriorsurface 31 of the base 22 by stitches 72 that extend around theperiphery of the spider member central portion 54.

The spider member 24 includes a first upper tensioning strap 62A, asecond upper tensioning strap 62B, a first lower tensioning strap 64A,and a second lower tensioning strap 64B extending from the centralportion 54. Each of the tensioning straps 62A, 62B, 64A, 64B terminatesin hook-type fastening tabs 66 suitable for detachable attachment to thefabric 28 on the exterior surface of the base 22 and sewn to thetensioning straps with stitches 68. The spider member 24 also has akneecap opening 70 to receive the kneecap when the brace is worn.

FIGS. 2A and 2B show exterior and interior plan views, respectively, ofa knee brace 120 according to the present invention laid flat. The kneebrace 120 includes a base member 122 and a spider member 124, each madeby cutting planar sheets 126 of an elastomeric material into the desiredshapes. The outer surface of the base member 122 is preferably coveredwith fabric bearing fiber loops 128 that adheres to hook-type materialwhen the fiber loops and hook-type material are pressed together.

The base 122 of the knee brace 120 has a base central portion 130extending vertically from an upper edge 136 to a lower edge 138, and hasa mid-line axis 140 running vertically down the middle of base centralportion 130. The base 122 includes a first upper mounting strap 132A, asecond upper mounting strap 132B, a first lower mounting strap 134A, anda base second lower mounting strap 134B extending from the centralportion 130.

As perhaps best shown in FIG. 2B which shows the interior surface 139 ofthe base 122, the first upper mounting strap 132A and first lowermounting strap 134A terminate in hook-type strap fastening tabs 146suitable for detachable attachment to the fabric bearing fiber loops 128on the external surface 131 of the base 122. The hook-type strapfastening tabs 146 are sewn to the mounting straps with stitches 148.

As best shown in FIGS. 4A and 4B, when the base 122 of the knee brace120 is applied to the leg of a person, the first upper mounting strap132A overlaps the second upper mounting strap 132B at the rear of theleg, allowing the hook-type fastening tab 146 at the end of the firstupper mounting strap 132A to adhere to the fabric bearing fiber loops128 on the exterior surface of the second upper mounting strap 132B inorder to fasten the knee brace 120 about the upper leg 142 of thewearer. Similarly, the first lower mounting strap 134A overlaps andadheres to the second lower mounting strap 134B at the rear of the legin order to fasten the knee brace 120 about the lower leg 144 of thewearer.

The base 122 also preferably has a kneecap opening 152 to receive thepatella (kneecap) when the brace is worn. The kneecap opening 152 canmatch the size of the kneecap, so that the kneecap of the wearer extendsfrom the kneecap opening 152 when the brace 120 is worn, although thisis not necessary. The kneecap opening 152 is preferably circular inshape, but this is not necessary and other shapes such as a diamond,oval, rectangle, or square shape may be used. In addition to providingdirect patella stabilization, the kneecap opening 152 may help to locatethe brace 120 with respect to the kneecap during application of thebrace 120.

The base 122 may be formed to include a recess 174 between the uppermounting straps 132A, 132B and the lower mounting straps 134A, 134B, sothat when the knee brace 120 is fitted upon the leg the gaps on eachside form an opening at the rear of the knee, although this is notrequired. The recess 174 can help to avoid chafing, it can provideventilation, and it can help avoid bunching or undue restriction ofmovement.

The base 122 is preferably formed, as shown in FIGS. 2A-2B, as areclosable sleeve made from a sheet of elastic material that providesgeneralized support and compression to the knee area, along withtherapeutic warming, but other materials may be used. The base 122 mayalso be formed, for example, as a tubular elastic sleeve shaped to fitsnugly about the knee and adjacent leg portions. The base preferablyincludes edge binding 176, although none of these features are required.

As perhaps best shown in FIG. 2B which shows the interior surface 139 ofthe base 122, the knee brace 120 includes a spider member 124. Thespider member 124 has a spider member central portion 154 extendingvertically from an upper edge 156 to a lower edge 158, and has amid-line axis 160 running vertically down the middle of the spidermember central portion 154. The central portion 154 of the spider member124 is permanently attached to the interior surface 139 of the base 122by stitches 171 that extend along the mid-line axis 160 of the spidermember central portion 54.

The spider member 124 includes a first upper tensioning strap 162A, asecond upper tensioning strap 162B, a first lower tensioning strap 164A,and a second lower tensioning strap 164B extending from the centralportion 154. Each of the tensioning straps 162A, 162B, 164A, 164Bterminates in hook-type fastening tabs 166 suitable for detachableattachment to the fabric bearing fiber loops 128 on the exterior surfaceof the base 122 and sewn to the tensioning straps with stitches 168. Thespider member 124 also has a kneecap opening 170 to receive the kneecapwhen the brace is worn.

While there are some similarities between the prior art knee brace 20and a knee brace 120 according to the present invention, there are(without limitation) at least three important differences. First, thespider member 24 of the prior art knee brace 20 is fastened to theexterior surface 31 of the base 22. In contrast, the spider member 124of the knee brace 120 according to the present invention is fastened tothe interior surface 139 of the base 122.

Second, the spider member 24 of the prior art knee brace 20 is fastenedto the base 22 by stitches 72 that extend around the periphery of thespider member central portion 54. In contrast, the spider member 124 ofthe knee brace 120 is fastened to the base 122 by stitches 171 thatextend along the mid-line axis 160 of the spider member central portion154.

Third, both the central portion 54 and the tensioning straps 62A, 62B,64A, 64B of the spider member 24 of the prior art knee brace 20 are onthe exterior surface 31 of the base 22 during normal use. In contrast,in the knee brace 120 the central portion 154 of the spider member 124is on the interior surface 139 of the base 122, and the tensioningstraps 162A, 162B, 164A, and 164B extend through apertures 133A, 133B,135A, 135B to reach the exterior surface 131 of the base 122.

FIGS. 5A-5B are plan views of a second embodiment of a knee braceaccording to the present invention 220, with the brace laid flat toexpose the exterior and interior surfaces of the brace. The knee brace220 has a shaped tensioning member 224 (shown in isolation in FIG. 5C)permanently fastened to the interior surface of the base. The knee brace220 also includes reinforced apertures 237 formed with an aperturereinforcement base 237A and aperture reinforcement backing 237B (shownin isolation in FIGS. 5D-5E).

The knee brace 220 includes a base member 222 and a shaped tensioningmember 224, each made by cutting planar sheets 226 of one or moreelastomeric materials into the desired shapes. The outer surface of thebase member 222 is preferably covered with fabric bearing fiber loops228 that adheres to hook-type material when the fiber loops andhook-type material are pressed together. The shaped tensioning member224 is preferably formed of a synthetic fiber that is relatively elasticin all directions for example of the type known as spandex in the UnitedStates or elasthane, or sold under the trademark LYCRA®, although thisis not required and other materials could be used.

The base 222 of the knee brace 220 has a base central portion 230extending vertically from an upper edge 236 to a lower edge 238, and hasa mid-line axis 240 running vertically down the middle of base centralportion 230. The base 222 includes a first upper mounting strap 232A, asecond upper mounting strap 232B, a first lower mounting strap 234A, anda base second lower mounting strap 234B extending from the centralportion 230. The base 222 also includes first upper aperture 233A,second upper aperture 233B, first lower aperture 235A, and second loweraperture 235B, all formed as reinforced apertures 237 in the base 222.

As perhaps best shown in FIG. 5B which shows the interior surface 239 ofthe base 222, the first upper mounting strap 232A and first lowermounting strap 234A terminate in hook-type strap fastening tabs 246suitable for detachable attachment to the fabric bearing fiber loops 228on the external surface 231 of the base 222. The hook-type strapfastening tabs 246 are sewn to the mounting straps with stitches 248.

The knee brace 220 is applied and fastened to the leg of a person in asimilar fashion as the knee brace 120 shown in FIGS. 3A-3B and 4A-4B.The base 222 also preferably has a kneecap opening 252 to receive thepatella (kneecap) when the brace is worn, and may be formed to include aside recess 274 between the upper mounting straps 232A, 232B and thelower mounting straps 234A, 234B. The base preferably includes edgebinding 276, although none of these features are required.

As perhaps best shown in FIG. 5B which shows the interior surface 239 ofthe base 222, the knee brace 220 includes a shaped tensioning member224. As perhaps best shown in FIG. 5C, the shaped tensioning member 224has a central portion 254, an upper edge 256, a lower edge 258, a firstlateral side 263A, a second lateral side 263B, and a central portionmid-line axis 260. The shaped tensioning member 224 also includes afirst upper tensioning strap 262A, a second upper tensioning strap 262B,a first lower tensioning strap 264A, and a second lower tensioning strap264B. The shaped tensioning member 224 terminates in hook-type fasteningtabs 266 suitable for detachable attachment to the fabric bearing fiberloops 228 on the exterior surface of the base 222 and sewn to thetensioning straps with stitches 268. The shaped tensioning member 224may include a kneecap opening 270, and may be permanently attached tothe base 222 by mid-line stitches 271 that extend along the mid-lineaxis 260 of the central portion 254.

FIGS. 6A-6B are plan views of a third embodiment of a knee braceaccording to the present invention 320, with the brace laid flat toexpose the exterior and interior surfaces of the brace. The knee brace320 has resilient stays and features upper and lower crossed elasticstraps permanently fastened to the interior surface of the base. Theknee brace 320 also includes reinforced apertures 337.

The knee brace 320 includes a base member 322 made by cutting planarsheets 326 of one or more elastomeric materials into the desired shape.The exterior surface 331 of the base member 322 is preferably coveredwith fabric bearing fiber loops 328 that adheres to hook-type materialwhen the fiber loops and hook-type material are pressed together. Theknee brace 320 also includes upper crossed straps 324 and lower crossedstraps 325, preferably formed of a material that is elastic along thelength of the straps.

The base 322 of the knee brace 320 has a base central portion 330extending vertically from an upper edge 336 to a lower edge 338, and hasa mid-line axis 340 running vertically down the middle of base centralportion 330. The base 322 includes a first upper mounting strap 332A, asecond upper mounting strap 332B, a first lower mounting strap 334A, anda base second lower mounting strap 334B extending from the centralportion 330. The base 322 also includes first upper aperture 333A,second upper aperture 333B, first lower aperture 335A, and second loweraperture 335B, all formed as reinforced apertures 337 in the base 322.

As perhaps best shown in FIG. 2B which shows the interior surface 339 ofthe base 322, the first upper mounting strap 332A and first lowermounting strap 334A terminate in hook-type strap fastening tabs 346suitable for detachable attachment to the fabric bearing fiber loops 328on the external surface 331 of the base 322. The hook-type strapfastening tabs 346 are sewn to the mounting straps with stitches 348.

The knee brace 320 is applied and fastened to the leg of a person in asimilar fashion as the knee brace 120 shown in FIGS. 3A-3B and 4A-4B.The base 322 also preferably has a kneecap opening 352 to receive thepatella (kneecap) when the brace is worn, and may be formed to include arecess 374 between the upper mounting straps 332A, 332B and the lowermounting straps 334A, 334B. The base preferably includes edge binding376, although none of these features are required.

As perhaps best shown in FIG. 6B which shows the interior surface 339 ofthe base 322, the knee brace 320 includes upper crossed straps 324 witha central portion 354 and lower crossed straps 325 with a centralportion 355. The crossed straps have a mid-line axis 360. The uppercrossed straps 324 comprise first upper crossed tensioning strap 362Aand second upper crossed tensioning strap 362B. The lower crossed straps325 comprise first lower crossed tensioning strap 364A and second lowercrossed tensioning strap 364B. The tensioning straps terminate inhook-type Velcro fastening tabs 366 suitable for detachable attachmentto the fabric bearing fiber loops 328 on the exterior surface of thebase 322 and sewn to the tensioning straps with stitches 368. The base322 may include a patella buttress 370. The upper crossed straps 324 andlower crossed straps 325 may be permanently attached to the base 322 bystitches 371 that extend along the mid-line axis 360 and by stiches363A, 363B, 365A, 365B at the fixed ends of the crossed straps.

The base 320 may include additional lateral support, for example one ormore resilient stays 382 (shown in FIG. 7E) placed in pockets 381 formedusing an additional sheet material secured to the base by resilient staychannel stitching 380.

FIGS. 7A-7B are plan views of a fourth embodiment of a knee braceaccording to the present invention 420, with the brace laid flat toexpose the exterior and interior surfaces of the brace. Similar to kneebrace 220 of FIGS. 5A-5B, the knee brace 420 has a shaped tensioningmember 424 (shown in isolation in FIG. 7C) formed of a synthetic fiberthat is relatively elastic in all directions and permanently fastened tothe interior surface of the base. The knee brace 420 also includesreinforced apertures 437 and an external mesh layer 480 (shown inisolation in FIG. 7D).

The knee brace 420 includes a base member 422 and a shaped tensioningmember 424, each made by cutting planar sheets 426 of one or moreelastomeric materials into the desired shapes. The outer surface of thebase member 422 is preferably covered with fabric bearing fiber loops428 that adheres to hook-type material when the fiber loops andhook-type material are pressed together. The shaped tensioning member424 is preferably formed of a synthetic fiber that is relatively elasticin all directions for example of the type known as spandex in the UnitedStates or elasthane, or sold under the trademark LYCRA®, although thisis not required and other materials could be used.

The base 422 of the knee brace 420 has a base central portion 430extending vertically from an upper edge 436 to a lower edge 438, and hasa mid-line axis 440 running vertically down the middle of base centralportion 430. The base 422 includes a first upper mounting strap 432A, asecond upper mounting strap 432B, a first lower mounting strap 434A, anda base second lower mounting strap 434B extending from the centralportion 430. The base 422 also includes first upper aperture 433A,second upper aperture 433B, first lower aperture 435A, and second loweraperture 435B, all formed as reinforced apertures 437 in the base 422.

As perhaps best shown in FIG. 7B which shows the interior surface 439 ofthe base 422, the first upper mounting strap 432A and first lowermounting strap 434A terminate in hook-type strap fastening tabs 446suitable for detachable attachment to the fabric bearing fiber loops 428on the external surface 431 of the base 422. The hook-type strapfastening tabs 446 are sewn to the mounting straps with stitches 448,and may include one or more flair devices 449, such as reflectors,lights, glow-in-the-dark materials, or bright colors.

The knee brace 420 is applied and fastened to the leg of a person in asimilar fashion as the knee brace 120 shown in FIGS. 3A-3B and 4A-4B.The base 422 also preferably has a kneecap opening 452 to receive thepatella (kneecap) when the brace is worn. The base 422 may be formed toinclude a recess 474 between the upper mounting straps 432A, 432B andthe lower mounting straps 434A, 434B. The base 422 can be formed usingmultiple sheets, or with a simple cut with stitching 453 to contour thebase to fit the leg more closely.

As perhaps best shown in FIG. 7B which shows the interior surface 439 ofthe base 422, the knee brace 420 includes a shaped tensioning member 424with a central portion 454, an upper edge 456, a lower edge 458, a firstlateral side 463A, a second lateral side 463B, and a central portionmid-line axis 460. The shaped tensioning member 424 also includes afirst upper tensioning strap 462A, a second upper tensioning strap 462B,a first lower tensioning strap 464A, and a second lower tensioning strap464B. As perhaps best shown in FIG. 7C, the tensioning straps mayinclude one or more inelastic portions 465.

The shaped tensioning member 424 terminates in hook-type fastening tabs466 suitable for detachable attachment to the fabric bearing fiber loops428 on the exterior surface of the base 422 and sewn to the tensioningstraps with stitches 468. The shaped tensioning member 424 may include akneecap opening 470, and may be permanently attached to the base 422 bymid-line stitches 471.

As perhaps best shown in FIG. 7A, the knee brace 420 includes anexternal mesh layer 480. As shown in FIG. 7D, the external mesh layer480 has an upper edge 481, a lower edge 482, a mid-line axis 484, anfirst upper arm 486A, a second upper arm 486B, a first lateral side487A, a second lateral side 487B, a first lower arm 488A, and a secondlower arm 488B. The exterior mesh layer 480 is permanently fastened tothe first upper tensioning strap near the first strap end, to the secondupper tensioning strap near the second strap end, to the first lowertensioning strap near the third strap end, and to the second lowertensioning strap near the fourth strap end. The exterior mesh layer 480may be otherwise unattached to the base 422.

FIGS. 8A-8B are plan views of a fifth embodiment of a knee braceaccording to the present invention 520, with the brace laid flat toexpose the exterior and interior surfaces of the brace. Similar to kneebrace 320 of FIGS. 6A-6B, the knee brace 520 has upper and lower crossedelastic straps permanently fastened to the interior surface of the base.The knee brace 520 also includes reinforced apertures 537 and resilientstays 582, and features an external mesh layer 590 (shown in isolationin FIG. 8D).

The knee brace 520 includes a base member 522 made by cutting planarsheets 526 of one or more elastomeric materials into the desired shape.The outer surface of the base member 522 is preferably covered withfabric bearing fiber loops 528 that adheres to hook-type material whenthe fiber loops and hook-type material are pressed together. The kneebrace 520 also includes upper crossed straps 524 and lower crossedstraps 525, preferably formed of a material that is elastic along thelength of the straps.

The base 522 of the knee brace 520 has a base central portion 530extending vertically from an upper edge 536 to a lower edge 538, and hasa mid-line axis 540 running vertically down the middle of base centralportion 530. The base 522 includes a first upper mounting strap 532A, asecond upper mounting strap 532B, a first lower mounting strap 534A, anda base second lower mounting strap 534B extending from the centralportion 530. The base 522 also includes first upper aperture 533A,second upper aperture 533B, first lower aperture 535A, and second loweraperture 535B, all formed as reinforced apertures 537 in the base 522.

As perhaps best shown in FIG. 8B which shows the interior surface 539 ofthe base 522, the first upper mounting strap 532A and first lowermounting strap 534A terminate in hook-type strap fastening tabs 546suitable for detachable attachment to the fabric bearing fiber loops 528on the external surface 531 of the base 522. The hook-type strapfastening tabs 546 are sewn to the mounting straps with stitches 548.

The knee brace 520 is applied and fastened to the leg of a person in asimilar fashion as the knee brace 120 shown in FIGS. 3A-3B and 4A-4B.The base 522 also preferably has a kneecap opening 552 to receive thepatella (kneecap) when the brace is worn. The base 522 may be formed toinclude a recess 574 between the upper mounting straps 532A, 532B andthe lower mounting straps 534A, 534B.

As perhaps best shown in FIG. 2B which shows the interior surface 539 ofthe base 522, the knee brace 520 includes upper crossed straps 524 witha central portion 554 and lower crossed straps 525 with a centralportion 555. The crossed straps have a mid-line axis 560. The uppercrossed straps 524 comprise first upper crossed tensioning strap 562Aand second upper crossed tensioning strap 562B. The lower crossed straps525 comprise first lower crossed tensioning strap 564A and second lowercrossed tensioning strap 564B. The tensioning straps terminate inhook-type Velcro fastening tabs 566 suitable for detachable attachmentto the fabric bearing fiber loops 528 on the exterior surface of thebase 522 and sewn to the tensioning straps with stitches 568. The base522 may include a patella buttress 570. The upper crossed straps 524 andlower crossed straps 525 may be permanently attached to the base 522 bymid-line stitches 571 that extend along the mid-line axis 560 and bystitches 563A, 563B, 565A, 565B at the fixed ends of the crossed straps.

The base 520 may include additional lateral support, for example one ormore resilient stays 582 placed in pockets 581 formed using anadditional sheet material secured to the base by resilient stay channelstitching 580.

As perhaps best shown in FIG. 8A, the knee brace 520 includes anexternal mesh layer 590. As shown in FIG. 8D, the external mesh layer590 has an upper edge 591, a lower edge 592, a mid-line axis 594, anfirst upper arm 596A, a second upper arm 596B, a first lateral side597A, a second lateral side 597B, a first lower arm 598A, and a secondlower arm 598B. The exterior mesh layer 590 is permanently fastened tothe first upper tensioning strap near the first strap end, to the secondupper tensioning strap near the second strap end, to the first lowertensioning strap near the third strap end, and to the second lowertensioning strap near the fourth strap end. The exterior mesh layer 590may be otherwise unattached to the base 522.

There are various possibilities with regard to alternative embodimentsof a knee brace according to the invention.

Although in a preferred embodiment the knee brace includes a base whichis formed as a reclosable sleeve made from a sheet of elastic material,this is not required. For example, the base may also be formed of atubular elastic sleeve shaped to fit snugly about the knee and adjacentleg portions. The base does not need to include a kneecap opening, andthe kneecap opening, if present, could have a variety of shapes, e.g.circular, square, rectangular, elliptical, diamond, trapezoidal, or anysubstantial equivalent. All such alternative embodiments will bereferred to herein as a base.

Although in a preferred embodiment the lateral sides of the base eachterminate in upper and lower fastening straps, with a side recessbetween the upper and lower fastening straps, this is not required. Forexample, the sides of the base, or portions thereof, could be straight.

Although in a preferred embodiment the base is detachably fastened aboutthe leg of the wearer using hook and loop material of the type whichadheres when pressed together, this is not required. For example, otherfasteners such as buttons, clasps, buckles, pins, zippers, straps,buttons or other substantial equivalents may be substituted for the hookand loop type fastener material.

Although in a preferred embodiment, various components are permanentlyfastened together using stitches, this is not required. For example,other means such as glue, thermal bonding, or other substantialequivalents could be used.

One or more upright support members may be provided on one side, or onboth sides, of the base of the knee brace, to provide support andprotect the knee against abnormal motions, although this is notrequired. The upright support members may be formed, for example, byplacing a resilient stay member in an elongated side pocket. Theresilient stay members may be comprised of a flattened spiral core ofstainless steel or other flexible material of conventional constructioncommonly used in various types of braces.

The elongate side pocket may be formed, for example, between verticalsewn seams that fix a side pocket cover strip to the base. The sidepocket cover strip may be made of the same elastic sheet material as thebase, although this is not necessary. Edge binding may be fastened tothe edges of the side pocket cover strips, although this is notnecessary.

The exact number, location, and construction of the upright supportmembers may vary if provided. For example, there may be a singleelongated side pocket forming only one upright support member, or theremay be one or more elongated side pockets on each side of the knee witha resilient stay in each elongated side pocket. The elongated sidepockets may be openable at one end to allow removal of the resilientstays, so that the brace may be washed or so that different resilientstays may be inserted to adjust the amount and type of support provided.The upright support members may include mechanical hinges, plastic rods,metal rods, narrow strips of reinforcing sheet material, or othersubstantial equivalents, or a combination of these various alternatives.

Advantageously, the external surface of the front of a knee braceaccording to the invention does not bear any structure, and can besmooth except for any stitches that secure the spider member to theinside of the base. The smooth external surface can be maintained, forexample to provide an attractive and clean appearance that will not snagor obstruct motion during use. Alternatively other structures such asthick knee pads for use in contact sports like football or in tradeslike concrete or floor tile work, or slippery material for use in sportslike volleyball, could be positioned on the external surface forparticular applications.

It is understood that the invention is not confined to the embodimentsset forth herein as illustrative, but embraces all such forms thereofthat come within the scope of the following claims.

What is claimed is:
 1. A knee brace, comprising: (a) a base wearable insnug covering relationship to portions of a knee and adjacent portionsof a leg of a person, the base having an exterior surface and aninterior surface when worn; and (b) a spider member having a first uppertensioning strap, a second upper tensioning strap, a first lowertensioning strap, and a second lower tensioning strap, wherein thespider member is permanently fastened to the interior surface of thebase.
 2. The knee brace of claim 1 wherein the base has a base centralportion mid-line axis, wherein the spider member has a spider membercentral portion mid-line axis, and wherein the spider member ispermanently fastened to the interior surface of the base by a pluralityof stitches through at least a portion of the base central portionmid-line axis and through at least a portion of the spider membercentral portion mid-line axis.
 3. The knee brace of claim 2 wherein theportion of the base central portion mid-line axis overlaps and alignswith the portion of the spider member central portion mid-line axis. 4.The knee brace of claim 1 wherein the base has a base kneecap opening,wherein the spider member has a spider member kneecap opening, andwherein the base kneecap opening is centered on the spider memberkneecap opening when worn.
 5. A knee brace, comprising: (a) a basewearable in snug covering relationship to portions of a knee andadjacent portions of a leg of a person, the base having an exteriorsurface and an interior surface when worn; and (b) a spider memberhaving a first upper tensioning strap, a second upper tensioning strap,a first lower tensioning strap, and a second lower tensioning strap,wherein the base has a base central portion mid-line axis, wherein thespider member has a spider member central portion mid-line axis, andwherein the spider member is permanently fastened to the base by aplurality of stitches through at least a portion of the base centralportion mid-line axis and through at least a portion of the spidermember central portion mid-line axis.
 6. The knee brace of claim 5wherein the spider member is permanently fastened to the interiorsurface of the base.
 7. The knee brace of claim 5 wherein the portion ofthe base central portion mid-line axis overlaps and aligns with theportion of the spider member central portion mid-line axis.
 8. The kneebrace of claim 5 wherein the spider member is not otherwise permanentlyfastened to the base.
 9. A knee brace, comprising: (a) a base wearablein snug covering relationship to portions of a knee and adjacentportions of a leg of a person, the base having an exterior surface andan interior surface when worn; and (b) a shaped tensioning member formedof a material that is elastic in all directions and having a first uppertensioning strap, a second upper tensioning strap, a first lowertensioning strap, and a second lower tensioning strap, wherein theshaped tensioning member is permanently fastened to the interior surfaceof the base.
 10. The knee brace of claim 9 wherein the base includes afirst upper aperture, a second upper aperture, a first lower aperture,and a second lower aperture; and wherein the first upper tensioningstrap extends through the first upper aperture to a first free strapend, wherein the second upper tensioning strap extends through thesecond upper aperture to a second strap end, wherein the first lowertensioning strap extends through the first lower aperture to a thirdstrap end, and wherein the second lower tensioning strap extends throughthe second lower aperture to a fourth strap end, and wherein the firststrap end, the second strap end, the third strap end and the fourthstrap end are detachably attachable to the exterior surface of the basewhen the brace is worn.
 11. The knee brace of claim 10 furthercomprising an exterior mesh layer permanently fastened to at least oneof the first upper tensioning strap, the second upper tensioning strap,the first lower tensioning strap, and the second lower tensioning strap.12. The knee brace of claim 11 wherein the exterior mesh layerpermanently fastened to the first upper tensioning strap near the firststrap end, the second upper tensioning strap near the second strap end,the first lower tensioning strap near the third strap end, and thesecond lower tensioning strap near the fourth strap end.
 13. A kneebrace, comprising: (a) a base wearable in snug covering relationship toportions of a knee and adjacent portions of a leg of a person, the basehaving an exterior surface and an interior surface when worn; and (b) aspider member having a plurality of tensioning straps, and wherein aportion of the spider member is positioned between the base and the legof the person when worn.
 14. The knee brace of claim 13 wherein theplurality of tensioning straps comprises a first upper tensioning strap,a second upper tensioning strap, a first lower tensioning strap, and asecond lower tensioning strap.
 15. The knee brace of claim 13 whereinthe base includes a plurality of apertures, and wherein each tensioningstrap in the plurality of tensioning straps extends through at least oneaperture in the plurality of apertures.
 16. A knee brace, comprising:(a) a base wearable in snug covering relationship to portions of a kneeand adjacent portions of a leg of a person, the base having an exteriorsurface and an interior surface when worn; and (b) a spider memberhaving a first upper tensioning strap, a second upper tensioning strap,a first lower tensioning strap, and a second lower tensioning strap,wherein a portion of the spider member is positioned between the baseand the leg of the person when worn.
 17. The knee brace of claim 16wherein the base has a base central portion, wherein the spider memberhas a spider member central portion, and wherein the spider member ispermanently fastened to the base at a point, where the point is locatedin the base central portion and the point is located in the spidermember central portion.
 18. The knee brace of claim 16 wherein the basehas a base central portion, wherein the spider member has a spidermember central portion, wherein the spider member is permanentlyfastened to the base at a plurality of points, and wherein the pluralityof points are located in the base central portion and the plurality ofpoints are located in the spider member central portion.
 19. The kneebrace of claim 18 wherein the plurality of points fall along a line. 20.The knee brace of claim 19 wherein the base has a mid-line axis, andwherein the line falls along the mid-line axis.